Collapsible dual-tier fire grate kit

ABSTRACT

A collapsible fire grate kit includes a pair of opposing support frames. A lower grate and an upper grate each include a plurality of elongated members for supporting logs. The elongated members of the lower and upper grates are removably supported on the first support frame and the second support frame. A pan disposed below the lower grate between the first support frame and the second support frame for collecting ash and for outwardly radiating heat. Each elongated member of the lower and upper grates define a pair of slots receiving the first support frame and the second support frame, respectively. The slots open downwardly and extend along the longitudinal axis with the first support frame and the second support frame extending through the slots transversely to the axis so that the lower and upper grates support the first and second support frames in upright positions.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 61/641,501 filed on May 2, 2012 and which is expressly incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention includes a collapsible fire grate kit, and, in particular, a dual-tier fire grate kit for supporting two tiers of logs.

2. Description of the Related Art

Fire grates are used for holding stacked logs for burning. Fire grates are typically used in fireplaces and in outdoor setting such as patios, yards, etc. The fire grate supports the wood in a stacked configuration spaced from the ground to allow for air flow to fuel the burn. A fire grate can include a single horizontal grate that supports a single tier of stacked logs. A stack of logs on the single horizontal grate will collapse during the burn and will require additional stoking, which disadvantageously results in rolling of the logs and embers popping from the logs.

Some fire grates include additional supports for supporting logs in specific orientations to aid in burning and ash collection. These additional supports can be welded to the rest of the fire grate, i.e., with a permanent connection. The shape of such a fire grate undesirably consumes a relatively large amount of space for shipping, storage, and transportation between uses. In other configurations, these additional supports can be connected to the rest of the fire grate with removable fasteners. However, such fasteners require awkward positioning and support of the components of the fire grate while the removable fasteners are being engaged/disengaged. The functionality of these removable fasteners can also be undesirably affected by ash build-up, corrosion, etc.

As such, there remains an opportunity to design an improved fire grate that is compactly shipped, stored, and transported and easily and effectively assembled.

SUMMARY OF THE INVENTION AND ADVANTAGES

One aspect of the present invention includes a collapsible fire grate kit comprising a first support frame including a lower bar and an upper bar spaced vertically from each other. A second support frame is spaced from the first support frame and includes a lower bar and an upper bar spaced vertically from each other. A lower grate is supported on the lower bars of the first and second support frames and extends along a longitudinal axis. The lower grate includes a plurality of elongated members spaced from each other and each extending along the longitudinal axis of the lower grate for supporting logs. An upper grate is vertically spaced above the lower grate and is supported on the upper bars of the first and second support frames and extends along a longitudinal axis in parallel with the longitudinal axis of the lower grate. The upper grate includes a plurality of elongated members spaced from each other and each extending along the longitudinal axis of the upper grate for supporting logs. A pan is disposed below the lower grate between the first support frame and the second support frame for collecting ash and for outwardly radiating heat. Each elongated member of the lower grate defines a pair of slots spaced along the longitudinal axis of the lower grate and is removably receiving the lower bars of the first and second support frames, respectively. Each elongated member of the upper grate defines a pair of slots spaced along the longitudinal axis of the upper grate and removably receives the upper bars of the first and second support frames, respectively. The lower bars and the upper bars extend transversely to the longitudinal axes. The slots open downwardly and extend along the longitudinal axes for supporting the first support frame and the second support frame in upright positions when the lower and upper bars engage the lower and upper grates, respectively, in the slots.

Another aspect of the present invention includes a collapsible fire grate kit comprising a pair of support frames spaced from each other along an axis. A lower grate includes a plurality of elongated members spaced from each other and each extending along the axis for supporting logs. The elongated members of the lower grate are removably supported the first support frame and the second support frame. An upper grate includes a plurality of elongated members spaced from each other and each extending along the axis for supporting logs. The elongated members of the upper grate are removably supported on the first support frame and the second support frame. A pan is disposed below the lower grate between the first support frame and the second support frame for collecting ash and for outwardly radiating heat. Each elongated member of the lower grate and the upper grate define a pair of slots receiving the first support frame and the second support frame, respectively. The slots open downwardly and extend along the longitudinal axis with the first support frame and the second support frame extending through the slots transversely to the axis so that the lower and upper grates support the first and second support frames in upright positions.

Since the slots open downwardly and extend along the longitudinal axis, the grates support the support frames in upright positions. The positioning of the support frames in the slot provides stability to the assembled fire grate kit such that the assembled fire grate kit is free standing once assembled.

Further, the fire grate kit is easily assembled and disassembled. The fire grate kit is assembled by merely placing the grates on the first and second support frames with the first and second support frames aligned with the slots on the elongated members of the grates. Since the slots are downwardly opening, the support frames enter into the slots when the grates are lowered onto the support frames. To disassemble the fire grate kit, the grates are merely lifted from the support frames do remove the support frames from the slots of the elongated members. The fire grate kit can be collapsed into a disassembled state for easy shipping, storage, and transportation.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a front perspective view of an assembled fire grate kit and logs stacked on the kit;

FIG. 2 is the front perspective view of the assembled kit of FIG. 1 without logs;

FIG. 3 is a side perspective view of the assembled kit;

FIG. 4A is a perspective view of the assembled kit with a pan of the kit in an assembled position;

FIG. 4B is a perspective view of the assembled kit with the pan sliding away from the rest of the kit;

FIG. 5 is an exploded view of the kit;

FIG. 6 is a side view of first and second support frames of the kit;

FIG. 7 is a perspective view of a portion of the a grate of the kit;

FIG. 8 is a perspective view of another embodiment of the kit including legs to space the pan from the ground and a windshield that is partly cut-away;

FIG. 9 is an exploded view of the embodiment of FIG. 8; and

FIG. 10 is a perspective view of the kit of FIGS. 1-7 in a disassembled state for shipping, storage, and/or transport.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a collapsible fire grate kit 10 is generally shown. The kit 10 is a dual-tier fire grate assembly. When assembled, the kit 10 supports two tiers of logs, as shown in FIG. 1. The logs 12 can be natural wood that is burned on the kit 10 or, alternatively, can be faux wood, e.g., ceramic, with gas lines (not shown) for supplying a flammable gas such that a flame on the faux wood gives the appearance of a natural wood fire.

The assembled kit 10 can be placed in a fireplace (not shown) inside a building and/or can be used outside, e.g., on a patio, lawn, etc. A first embodiment shown in FIGS. 1-7 and 10 is typically used in a fireplace and a second embodiment shown in FIGS. 8 and 9 is raised, for example, for use outdoors. When used outdoors, the kit 10 can include a windscreen 14 for blocking wind and containing heat emitted from the fire, as shown in FIG. 8. The windscreen 14 can be of any shape and size without departing from the nature of the present invention.

The first embodiment of the kit 10 is shown in an assembled state in FIGS. 2-4B and the second embodiment of the kit 10 is shown in an assembled state in FIG. 8. The first embodiment of the kit 10 is shown in a disassembled state in FIG. 10. As set forth below, the second embodiment of the kit 10 can be similarly separated into the disassembled state.

With reference to FIGS. 1-5, the kit 10 includes a pair of opposing support frames 16, 18, a lower grate 20 for supporting a tier of logs 12, an upper grate 22 for supporting a tier of logs 12, and a pan 24 for collecting ash and outwardly radiating heat. The kit 10 is shown in the Figure with the lower grate 20 and the upper grate 22, i.e., two grates. Alternatively, the kit 10 can have three or more grates without departing from the nature of the present invention. It should be appreciated that the kit 10 can be assembled in a single grate configuration, e.g., with the lower grate 20 assembled to the pair of opposing support frames 16, 18 and without the upper grate 22 assembled to the opposing support frames 16, 18, or with the upper grate 22 assembled to the opposing support frames 16, 18 without the lower grate 20 assembled to the opposing support frames 16, 18.

The support frames 16, 18, the grates 20, 22, and the pan 24 are typically formed of heat-treated steel, but alternatively, can be formed of any type of material suitable to withstand fire. The support frames 16, 18, grates 20, 22, and pan 24 can be formed from a continuous sheet of metal, e.g., heat-treated steel, by laser cutting the components to their respective dimensions. The sheet of metal is heat treated and coated to provide durability and reduce the potential of oxidation known to occur on non-treated metal substrates. Alternatively, the components can be formed from untreated sheet metal and subsequently provided with a protective coating after laser cutting. Alternatively, the components can be manufactured in any fashion without departing from the nature of the present invention.

The pair of support frames 16, 18 includes a first support frame 16 and a second support frame 18. With reference to FIGS. 2-4B, the assembled kit 10 is elongated along an axis A. When the kit 10 is assembled, the support frames 16, 18 are spaced from each other along the axis A and support the lower grate 20 and the upper grate 22, as set forth further below.

The first support frame 16 and the second support frame 18 are shown in isolation in FIG. 6. The first support frame 16 and the second support frame 18 are typically flat. Typically, the entire first support frame 16 is flat and the entire second support frame 18 is flat. Alternatively, the first support frame 16 and the second support frame 18 can include curved features (not shown), lateral features, such as tracks described below, etc.

With continued reference to FIG. 6, each of the first support frame 16 and the second support frame 18 includes a lower bar 26 and an upper bar 28 spaced vertically from each other. When the kit 10 is assembled, the lower bars 26 support the lower grate 20 and the upper bars 28 support the upper grate 22, as set forth further below. The lower bars 26 and the upper bars 28 can define slots 30 configured to receive the lower grate 20 and the upper grate 22, respectively. When the kit 10 is assembled, the first side frame and the second side frame each include an extension 32 extending upwardly from the upper bar 28 for retaining logs 12 on the upper grate 22.

When the kit 10 is assembled, the lower grate 20 is supported on the lower bars 26 of the first and second support frames 16, 18. The lower grate 20 extends along a longitudinal axis AL (identified for example in FIG. 5) from the first support frame 16 to the second support frame 18. The longitudinal axis AL of the lower grate 20 is typically parallel with the axis A of the assembled kit 10. The lower grate 20 can be concave for containing the logs, i.e., such that the logs 12 roll toward a middle of the lower grate 20 as the logs 12 burn.

The lower grate 20 includes a plurality of elongated members 34 spaced from each other. Each elongated member 34 of the lower grate 20 extends along the longitudinal axis AL of the lower grate 20 and extends along the axis A of the assembled kit 10. The lower grate 20 includes cross members 36 fixed to and extending transverse to the elongated members 34. The cross members 36 can be welded to the elongated members 34. Prior to welding, the cross members 36 and the elongated members 34 can include interconnected mating slots (not shown) such that minimal spot welding is applied to the intersection of the elongated members 34 and the cross members 36. Alternatively, the cross members 36 and the elongated members 34 can be fixed to each other in any fashion without departing from the nature of the present invention.

When the kit 10 is assembled, the upper grate 22 is vertically spaced above the lower grate 20 for supporting logs 12. The upper grate 22 is supported on the upper bars 28 of the first and second support frames 16, 18. The upper grate 22 extends along a longitudinal axis AU (identified for example in FIG. 5). The longitudinal axis AU of the upper grate 22 extends in parallel with the longitudinal axis AL of the lower grate 20. The longitudinal axis AU of the upper grate 22 is typically parallel with the axis A of the assembled kit 10. The upper grate 22 can be concave for containing the logs, i.e., such that the logs 12 roll toward a middle of the upper grate 22 as the logs 12 burn.

The upper grate 22 includes a plurality of elongated members 35 spaced from each other. Each elongated member 35 of the upper grate 22 extends along the longitudinal axis AU of the upper grate 22 and extends along the axis A of the assembled kit 10. The upper grate 22 includes cross members 37 fixed to and extending transverse to the elongated members 35. The cross members 37 can be welded to the elongated members 35. Prior to welding, the cross members 37 and the elongated members 35 can include interconnected mating slots (not shown) such that minimal spot welding is applied to the intersection of the elongated members 35 and the cross members 37. Alternatively, the cross members 37 and the elongated members 35 can be fixed to each other in any fashion without departing from the nature of the present invention.

The elongated members 34 of the lower grate 20 are removably supported on the first support frame 16 and the second support frame 18, e.g., on the lower bars 26, and the elongated members 35 of the upper grate 22 are removably supported on the first support frame 16 and the second support frame 18, e.g., the upper bars 28. Each elongated member 34, 35 of the lower grate 20 and the upper grate 22 define a pair of slots 38 (identified in FIGS. 5 and 7) receiving the first support frame 16 and the second support frame 18, respectively. The slots 38 receive the first support frame 16 and the second support frame 18 and are retained in place on the first support frame 16 and the second support frame 18 under the weight of the lower grate 20 and the upper grate 22. Specifically, each elongated member 34 of the lower grate 20 defines a pair of slots 38 spaced along the longitudinal axis AL of the lower grate 20 and removably receiving the lower bars 26 of the first and second support frames 16, 18, respectively. Each elongated member 35 of the upper grate 22 defines a pair of slots 38 spaced along the longitudinal axis AU of the upper grate 22 and removably receiving the upper bars 28 of the first and second support frames 16, 18, respectively.

The slots 38 open downwardly and extend along the axis A. The first support frame 16 and the second support frame 18 extend through the slots 38 transversely to the axis A so that the lower and upper grates 20, 22 support the first and second support frames 16, 18 in upright positions. Specifically, the lower bars 26 and the upper bars 28 extend transversely to the longitudinal axes AL, AU. The slots 38 open downwardly and extend along the longitudinal axes AL, AU for supporting the first support frame 16 and the second support frame 18 in upright positions when the lower and upper bars 28 engage the lower and upper grates 20, 22, respectively, in the slots 38.

The engagement of the first and second support frames 16, 18 by the slots 38 of the elongated members of both grates 20, 22 locks the first and second support frames 16, 18 relative to each other and the weigh of the grates 20, 22 maintains engagement of the first and second support frames 16, 18 with the slots 38. In other words, the walls of the slots 38 prevent movement of the first and second support frames 16, 18 relative to the grates 20, 22 along the axis A. The interlocking of both the lower grate 20 and the upper grate 22 with both the first and second support frames 16, 18 provides stability such that the assembled kit 10 is free standing.

The first support frame 16 and the second support frame 18 are interconnected only by the lower grate 20 and the upper grate 22. In other words, when the lower grate 20 and the upper grate 22 are assembled to the first support frame 16 and the second support frame 18, the assembled kit 10 is free standing. The force of gravity on the grates 20, 22 maintains engagement of the lower bars 26 and the upper bars 28 with the slots, i.e., free of external fasteners, supports, etc. In other words, the weight of the grates 20, 22 acts against the lower bars 26 and the upper bars 28 to maintain engagement of the downwardly opening slots with the lower bars 26 and the upper bars 28.

The elongated members 34, 35 typically engage the first support frame 16 and the second support frame 18, e.g., the lower bars 26 and the upper bars 28, by snap-fit engagement. In other words, the slots 38 and the upper bars 28 and lower bars 26 are sized such that the bars 26, 28 snap into the slots 38.

As set forth above, the lower bars 26 of the first and second support frames 16, 18 can define slots 30 for receiving the elongated members 34, 35 of the lower grate 20 and the upper bars 28 of the first and second support frames 16, 18 can define slots 30 for receiving the elongated members 34, 35 of the upper grate 22. The slots 30 of the support frames 16, 18 can engage the slots 38 of the elongated members 34, 35 when the grates 20, 22 are assembled to the support frames 16, 18. The slots 38 on the elongated members 34, 35 and/or the slots 30 on the support frames 16, 18 can be chamfered to aid in alignment and engagement.

The pan 24 is disposed below the lower grate 20 between the first support frame 16 and the second support frame 18 for collecting ash and for outwardly radiating heat. The pan 24 is removable from the kit 10 for emptying contents of the pan 24. For example, as shown in FIG. 4B, the pan 24 can be slidable received between the first support frame 16 and the second support frame 18. The pan 24 can include a cutout for grasping the pan 24 to remove the pan 24 from the kit 10. The pan 24 is typically laser cut from a continuous sheet of metal, e.g., heat-treated steel, to predetermined dimensions and machine folded to form the pan 24. Corners of the pan 24 are welded and grounded to remove sharp edges.

The pan 24 can define perforated knock-outs 48 for being selectively removed to receive a gas line (not shown). The perforated knock-outs 48 are retained in the pan 24 when the kit 10 is used to burn logs 12 and one or both knock-outs 48 can be selectively removed to receive one or more gas lines. The perforated knock-outs 48, for example, can be removed by exerting force on the knock-outs 48 with a tool such as pliers, a hammer, etc.

With reference to FIGS. 3-4B, the first support frame 16 and the second support frame 18 each include a base 40 and only contact the ground along the base 40. The base 40 of the first support frame 16 extends along a straight line L and the base of the second support frame 18 extends along a straight line L.

With reference to FIGS. 8 and 9, in another embodiment the first support frame 16 and the second support frame 18 each include legs 42. The first support frame 16 and the second support frame 18 only contact the ground at the legs 42. The legs 42 of the first support frame 16 are spaced along a straight line L and the legs 42 of the second support frame 18 are spaced along a straight line L.

With continued reference to FIGS. 8 and 9, the legs 42 each define bottoms 44 for supporting the first and second support frames 16, 18 on ground. The first support frame 16 and the second support frame 18 each define a track 46 spaced from the bottoms 44 of the legs 42 and configured to slideably receive the pan 24.

With reference to FIG. 10, the support frames 16, 18, grates 20, 22, and pan 24 can be disassembled and packed together for easy shipping, storage, and/or transport between uses. To disassemble, the grates 20, 22 are lifted from the support frames 16, 18 such that the slots lift up from the lower bars 26 and upper bars 28. Once the grates 20, 22 are disengaged, the entire kit 10 is disassembled into five components and can be stacked as shown in FIG. 10. To reassemble, the slots of the lower grate 20 are engaged with the lower bars 26 of the first and second support frame 16, 18 and the slots of the upper grate 22 are engaged with the upper bars 28 of the first and second support frames 16, 18. As set forth above, FIG. 10 shows the embodiment of FIGS. 1-7 in a disassembled state and it should be appreciated that the embodiment of FIGS. 8-9 can similarly be disassembled.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described. 

What is claimed is:
 1. A collapsible fire grate kit comprising: a first support frame including a lower bar and an upper bar spaced vertically from each other; a second support frame spaced from said first support frame and including a lower bar and an upper bar spaced vertically from each other; a lower grate supported on said lower bars of said first and second support frames and extending along a longitudinal axis, said lower grate including a plurality of elongated members spaced from each other and each extending along said longitudinal axis of said lower grate for supporting logs; an upper grate vertically spaced above said lower grate and supported on said upper bars of said first and second support frames and extending along a longitudinal axis in parallel with said longitudinal axis of said lower grate, said upper grate including a plurality of elongated members spaced from each other and each extending along said longitudinal axis of said upper grate for supporting logs; a pan disposed below said lower grate between said first support frame and said second support frame for collecting ash and for outwardly radiating heat; each elongated member of said lower grate defining a pair of slots spaced along said longitudinal axis of said lower grate and removably receiving said lower bars of said first and second support frames, respectively; each elongated member of said upper grate defining a pair of slots spaced along said longitudinal axis of said upper grate and removably receiving said upper bars of said first and second support frames, respectively; said lower bars and said upper bars extending transversely to said longitudinal axes, said slots opening downwardly and extending along said longitudinal axes for supporting said first support frame and said second support frame in upright positions when said lower and upper bars engage said lower and upper grates, respectively, in said slots.
 2. The collapsible fire grate kit as set forth in claim 1 wherein the weight of the lower grate and the upper grate maintains engagement of said lower bars and said upper bars, respectively, in said slots.
 3. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame are interconnected only by said lower grate and said upper grate.
 4. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame are flat.
 5. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame each include a base and only contact the ground along said base, said base of said first support frame extending along a straight line and said base of said second support frame extending along a straight line.
 6. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame each include legs and only contact the ground at said legs, said legs of said first support frame spaced along a straight line and said legs of said second support frame spaced along a straight line.
 7. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame are spaced from each other along said longitudinal axes.
 8. The collapsible fire grate kit as set forth in claim 1 wherein said lower bars of said first and second support frames define slots for receiving said elongated members of said lower grate and wherein said upper bars of said first and second support frames define slots for receiving said elongated members of said upper grate.
 9. The collapsible fire grate kit as set forth in claim 8 wherein said slots of said elongated members of said lower grate engage said slots of said lower bars and wherein said slots of said elongated members of said upper grate engage said slots of said upper bars.
 10. The collapsible fire grate kit as set forth in claim 1 wherein said lower grate includes cross members fixed to and extending transverse to said longitudinal members and said upper grate includes cross members fixed to and extending transverse to said longitudinal members.
 11. The collapsible fire grate kit as set forth in claim 1 wherein said first side frame and said second side frame each include an extension extending upwardly from said upper bar for retaining logs on said upper grate.
 12. The collapsible fire grate kit as set forth in claim 1 wherein said lower grate and said upper grate are concave for containing the logs.
 13. The collapsible fire grate kit as set forth in claim 1 wherein said pan is slideably received between said first support frame and said second support frame.
 14. The collapsible fire grate kit as set forth in claim 1 wherein said pan defines perforated knock-outs for being selectively removed to receive a gas line.
 15. The collapsible fire grate kit as set forth in claim 1 wherein said first support frame and said second support frame each include legs.
 16. The collapsible fire grate kit as set forth in claim 15 wherein said legs each define bottoms for supporting said first and second support frames on ground and wherein said first support frame and said second support frame each define a track spaced from said bottoms of said legs and configured to slideably receive said pan.
 17. A collapsible fire grate kit comprising: a pair of support frames spaced from each other along an axis; a lower grate including a plurality of elongated members spaced from each other and each extending along said axis for supporting logs, said elongated members of said lower grate removably supported on said first support frame and said second support frame; an upper grate including a plurality of elongated members spaced from each other and each extending along said axis for supporting logs, said elongated members of said upper grate removably supported on said first support frame and said second support frame; a pan disposed below said lower grate between said first support frame and said second support frame for collecting ash and for outwardly radiating heat; each elongated member of said lower grate and said upper grate defining a pair of slots receiving said first support frame and said second support frame, respectively; said slots opening downwardly and extending along said longitudinal axis with said first support frame and said second support frame extending through said slots transversely to said axis so that said lower and upper grates support said first and second support frames in upright positions.
 18. The collapsible fire grate kit as set forth in claim 17 wherein said first support frame and said second support frame are interconnected only by said lower grate and said upper grate.
 19. The collapsible fire grate kit as set forth in claim 17 wherein said first support frame and said second support frame are flat. 